Tobacco-Containing Wrapper Having A White Brilliant Appearance

ABSTRACT

A wrapping material is disclosed that contains from about 10% to about 60% of a tobacco material. The tobacco material has a relatively large particle size. For instance, the tobacco material may have a particle size distribution such that greater than 80% of the tobacco particles and fibers have a greatest dimension of greater than about 0.025 inches. The tobacco material is combined with bleached pulp fibers and a filler and formed into a web using a papermaking process. The wrapping material has a distinct natural appearance and a less papery taste in relation to conventional cigarette papers. The wrapping material has a brighter, whiter look than conventional reconstituted tobacco wrappers and produces a smoother smoke with better ash appearance.

RELATED APPLICATIONS

This application is based upon and claims priority to U.S. Patent Application Ser. No. 62/741,898, filed on Oct. 5, 2018, which is incorporated herein by reference in its entirety.

BACKGROUND

Smoking articles, such as cigarettes or little cigars, are conventionally made by wrapping a column of tobacco in a wrapping material, made of cigarette paper or homogenized tobacco. At one end, the smoking article usually includes a filter or a tip through which the article is smoked. Filters are attached to smoking articles using a tipping paper that is glued to the wrapping paper. When the article is smoked, mainstream smoke is generated that is inhaled through the filter. Mainstream smoke can contain numerous components that provide the smoking article with a particular taste, which encompasses the sensations detected not only by one's taste, but also by one's sense of smell.

In order to be successful, in general, the wrapping material, when made of cigarette paper, should have a white and “clean” look. The wrapping material should also be made from materials and have a porosity that generates a mainstream smoke having a sufficient combustibility and desired taste for the user. In addition, a wrapping material should produce a cohesive ash that has a white appearance.

In the past, those skilled in the art have attempted to produce a wrapping material that improves the overall smoking experience of the smoking article. Wrapping cigarette papers were typically formed from pulp fibers, such as wood or flax fibers, combined with filler particles. Although wrapping cigarette papers can be produced having a white color, such wrapping papers produce a “papery” taste. Wrapping homogenized tobacco materials, on the other hand, were typically made of processed tobacco by-products in an amount greater than 50% and could not achieve satisfying ash appearance or combustibility.

In view of the above, a need exists for a wrapping material for smoking articles that can improve the taste of the smoking article. In particular, a need exists for a wrapping material that can reduce the papery taste of conventional cigarette paper materials. In addition, a need exists for a wrapping material that can be used in different types of smoking articles and that can have a white appearance.

SUMMARY

In general, the present disclosure is directed to a wrapping material for smoking articles that has a distinct natural appearance and produces a less papery taste than conventional wrapping papers. In accordance with the present disclosure, the wrapping material is constructed partially from tobacco material. The tobacco material is combined with cellulose fibers and a filler. In accordance with the present disclosure, the tobacco material is relatively unrefined when combined with the cellulosic fibers and has a relatively large particle size that has been found to convey many benefits and advantages.

In one embodiment, for example, the present disclosure is directed to a wrapping material for smoking articles. The wrapping material is made from a web containing at least 10% by weight of a tobacco material. The tobacco material can be substantially unrefined and/or can have a particle size distribution such that over 80% of the tobacco material has a longest dimension of greater than about 0.012 inch, such as greater than about 0.015 inch. The tobacco material can comprise tobacco fibers, tobacco particles, or mixtures thereof. In one embodiment, more than 50% of the tobacco material, such as more than 60% of the tobacco material comprises flue cured stems. The tobacco material is generally contained in the web in an amount greater than about 10% by weight, such as in an amount from about 10% to about 60% by weight, such as from about 20% to about 40% by weight.

In accordance with the present disclosure, the tobacco material as described above is combined with bleached pulp fibers and a filler in producing the web. The bleached pulp fibers can be present in the web in an amount greater than about 20% by weight, such as in an amount from about 20% to about 50% by weight, such as in an amount from about 20% to about 40% by weight. The filler, on the other hand, comprises white particles and is present in the web in an amount greater than about 10% by weight, such as in an amount from about 10% to about 30% by weight, such as in an amount from about 15% to about 25% by weight. In one embodiment, the filler may comprise calcium carbonate particles.

Wrapping materials made in accordance with the present disclosure can have a brilliant white appearance. For instance, at least one side of the wrapping material may exhibit an L value of greater than about 65, such as greater than about 70, such as even greater than about 78. In addition to having an excellent white color, the material can also be relatively strong having a tensile strength of greater than about 1500 cN/15 mm.

In addition to the tobacco material, the bleached cellulosic fibers, and the filler, the wrapping material can also contain various other additives and ingredients. For instance, in one embodiment, the wrapping material can contain a humectant and/or a burn control agent. The humectant, for instance, may comprise glycerol, propylene glycol, or mixtures thereof. The burn control agent, on the other hand, may comprise a citrate, such as sodium citrate or potassium citrate, or mixtures thereof.

The resulting wrapping material or web can generally have an inherent porosity of from about 30 Coresta to about 80 Coresta, such as from about 40 Coresta to about 60 Coresta. The web can generally have a basis weight of from about 30 gsm to about 50 gsm. In one embodiment, the wrapping material can be calendered in order to provide a smooth uniform finish.

The wrapping material can be incorporated into all different types of smoking articles. In one embodiment, a smoking article is formed by surrounding a column of smokable tobacco filler with the wrapping material. The smoking article can comprise, for instance, a cigarette, a cigar, or a cigarillo.

Other features and aspects of the present disclosure are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present disclosure is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1 is a perspective view of one embodiment of a smoking article incorporating the wrapper of the present disclosure;

FIG. 2 is an exploded view of the smoking article illustrated in FIG. 1; and

FIG. 3 is another embodiment of a smoking article incorporating a wrapper made in accordance with the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.

In general, the present disclosure is directed to a wrapping material for smoking articles, such as cigarettes, little cigars, cigarillos, and larger cigars. The wrapping material contains a tobacco material in a relatively unrefined state that has a relatively large particle or fiber size. The tobacco material is combined with other materials to provide an overall wrapper that has a less papery taste than conventional cigarette wrapping papers. Of particular advantage, the wrapping material of the present disclosure not only has improved taste, but also has a natural appearance and a bright, white color. The wrapping material produces a cohesive and white ash and has better burning properties than many reconstituted tobacco wrappers made in the past.

In accordance with the present disclosure, an extracted tobacco material is combined with bleached pulp fibers and a filler to produce the wrapping material. Optionally, the material can also include various other ingredients and components. For instance, in one embodiment, a humectant can be added to the wrapping material. In an alternative embodiment, a burn control agent can be added to the wrapping material.

The tobacco material incorporated into the wrapper of the present disclosure can first be subjected to an extractant process where water soluble components are removed from the tobacco material. For example, in one embodiment, a tobacco furnish containing tobacco stems (e.g., flue-cured stems), fines and/or other tobacco by-products from tobacco manufacturing processes is initially mixed with a solvent (e.g., water and/or other compounds). In one embodiment, the solvent comprises only water. In an alternative embodiment, various solvents that are water-miscible, such as alcohols (e.g., ethanol), can be combined with water to form an aqueous solvent. The water content of the aqueous solvent can, in some instances, be greater than 50 wt. % of the solvent, and particularly greater than 90 wt. % of the solvent. Deionized water, distilled water or tap water may be employed. The amount of the solvent in the suspension can vary widely, but is generally added in an amount from about 50 wt. % to about 99 wt. %, in some embodiments from about 60 wt. % to about 95 wt. %, and in some embodiments, from about 75 wt. % to about 90 wt. % of the suspension. However, the amount of solvent can vary with the nature of the solvent, the temperature at which the extraction is to be carried out, and the type of tobacco furnish.

After forming the solvent/tobacco furnish mixture, some or all of a soluble fraction of the furnish mixture may be separated from the mixture. The aqueous solvent/tobacco furnish mixture can be agitated by stirring, shaking or otherwise mixing the mixture in order to increase the rate of solubilization. Typically, the process is carried out for about one-half hour to about 6 hours. Process temperatures may range from about 10° C. to about 100° C., such as from about 40° C. to about 80° C.

After the tobacco materials are soaked in an extractant, the tobacco material can be mechanically separated from the tobacco liquor using a press. Once the soluble fraction is separated from the tobacco furnish or insoluble fraction, the soluble fraction can be concentrated. The soluble fraction can be concentrated using any known type of concentrator, such as a vacuum evaporator. In one embodiment of the present disclosure, the soluble fraction can be highly concentrated. In one embodiment, for instance, the tobacco soluble fraction can be evaporated so as to have a final brix of from about 20% to about 40%, such as from about 25% to about 35%.

The resulting concentrated tobacco soluble fraction may be discarded, used in a separate process, or can be later coated onto the wrapping material of the present disclosure as will be described in greater detail below.

The resulting water insoluble tobacco fraction is generally in an unrefined state. The tobacco material can comprise particles and fibers. The tobacco material, for instance, may include stems, scraps, dust, tobacco leaves, and the like. In one embodiment, the tobacco material contains significant amounts of flue cured stems. For example, in one embodiment, the tobacco material contains flue cured stems in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, such as in an amount greater than about 70% by weight, by weight, such as in an amount greater than about 80% by weight, such as in an amount greater than about 90% by weight. The presence of large amounts of flue cured stems is believed to not only improve the appearance of the resulting wrapper material but also improve various other characteristics including mechanical properties and taste.

The insoluble fraction or extracted tobacco material is then mixed with pulp fibers, such as wood pulp fibers. More particularly, the water insoluble tobacco material is combined with bleached pulp fibers. The bleached pulp or cellulosic fibers can be obtained, for instance, from flax, softwood, or hardwood. The pulp fibers are bleached in order to lighten the color of the fibers and increase the whiteness of the final product. Using bleached pulp fibers can also improve the brightness of the wrapper material.

The tobacco material can be combined with the bleached pulp fibers generally in a weight ratio of from about 1:5 to about 3:1. For instance, the weight ratio between the tobacco material and the bleached pulp fibers can generally be greater than about 2:5, such as greater than about 4:5, and generally less than about 2:1, such as less than about 3:2, such as less than about 5:4.

Once the tobacco material is mixed with the bleached pulp fibers, the resulting blend can be refined using optionally disc refiners. For instance, the blend of materials can be refined in order to control the final porosity of the wrapping material.

In accordance with the present disclosure, in addition to refining the tobacco material and bleached pulp fibers, the tobacco and bleached pulp fibers can also be screened to control the particle size of the tobacco material. For example, either the blend or the tobacco material only can be fed through a screening process in order to remove larger sized particles and fibers. In one embodiment, for instance, the tobacco material or the blend of the tobacco material and the bleached pulp fibers can be fed through a screening device that has an opening size of from about 0.012 inches to about 0.015 inches.

The resulting tobacco material has a particle size distribution such that greater than 70% of the particles and fibers have a largest dimension or diameter of greater than 0.012 inches. For instance, the tobacco material can have a particle size distribution such as greater than about 80%, such as greater than about 90% of the particles and fibers have a largest particle dimension of greater than about 0.012 inches. In an alternative embodiment, the tobacco material has a particle size distribution such that greater than about 70%, such as greater than about 80%, such as greater than about 90% of the particles and fibers have a greatest dimension of greater than about 0.015 inches. In still another embodiment, the tobacco material has a particle size distribution such that greater than about 70%, such as greater than about 80%, such as greater than about 90% of the particles and fibers have a largest dimension of greater than about 0.025 inches.

In general, the largest particles and fibers contained in the tobacco material have a largest dimension of less than about 0.1 inches, such as less than about 0.08 inches, such as less than about 0.05 inches. For example, in one embodiment, greater than about 80%, such as greater than about 90%, such as greater than about 95% of the tobacco particles and fibers have a greatest dimension of less than about 0.05 inches.

It is believed that the above particle size distribution of the tobacco material provides various benefits and advantages. The above particle size distribution in conjunction with the use of refined tobacco material when combined with the pulp fibers is believed to produce a wrapping material with improved sensory attributes and improved appearance. The above particle size distribution of the tobacco material, for instance, produces a wrapping material having a natural appearance while also exhibiting a white color.

In forming the wrapping material of the present disclosure, the tobacco material as described above blended with the bleached pulp fibers are combined with a filler. The filler generally comprises white particles. The filler particles, for instance, may comprise calcium carbonate particles, titanium oxide particles, clay particles, magnesium oxide particles, mixtures thereof, and the like.

The particles can have any suitable particle size and shape. For instance, in one embodiment, the filler particles have a particle size of greater than about 0.1 microns, such as greater than about 0.2 microns, such as greater than about 0.3 microns. The particle size of the filler is generally less than about 2 microns, such as less than about 1.5 microns, such as less than about 1 micron, such as less than about 0.8 microns. In one embodiment, the median particle size of the filler is from about 0.1 microns to about 0.5 microns, such as from about 0.2 microns to about 0.4 microns. The filler particles can further increase the whiteness and brightness of the resulting wrapping material. In addition, the filler particles can also adjust the final porosity and combustibility of the wrapping material.

In one embodiment, the filler incorporated into the wrapping material is comprised of calcium carbonate particles. In one embodiment, the calcium carbonate particles may comprise precipitated particles. The calcium carbonate particles can have a rhombohedral shape in one embodiment. In an alternative embodiment, the calcium carbonate particles can have a non-isometric shape having a mean diameter of from about 50 nanometers to about 3 micrometers. The particles can have, for instance, an aspect ratio of generally greater than about 1, such as greater than about 2, such as greater than about 5, and generally less than about 15, such as less than about 12, such as less than about 10.

The filler is combined with the tobacco material and bleached pulp fibers in the presence of water to form a slurry. The fiber slurry is then used to form a continuous sheet. For example, in one embodiment, the fiber slurry is fed to a papermaking process that can include a forming wire, gravity drain, suction drain, a felt press, and a dryer, such as a Yankee dryer, a drum dryer, or the like. For example, in one embodiment, the fiber slurry is formed into a continuous sheet on a Fourdrinier table.

In one embodiment, for instance, the fiber slurry is laid onto a porous forming surface and formed into a sheet. Excess water is removed by a gravity drain and/or a suction drain. In addition, various presses can be used to facilitate water removal. The formed sheet can be dried and further treated.

In one embodiment, for instance, a humectant can be incorporated into the wrapping material. The humectant, for instance, may comprise glycerol, propylene glycol, or mixtures thereof and the like.

In addition to a humectant, one or more burn control agents can also be incorporated into the formed wrapper or paper. The burn control agent, for instance, may comprise a salt of a carboxylic acid, an alkali metal salt, and/or an alkaline earth metal salt. For example, the burn control agent may comprise a salt of acetic acid, citric acid, malic acid, lactic acid, tartaric acid, carbonic acid, formic acid, propionic acid, glycolic acid, fumaric acid, oxalic acid, malonic acid, succinic acid, nitric acid, phosphoric acid, or mixtures thereof. Particular burn controlling agents that may be used include potassium citrate, sodium citrate, potassium succinate, sodium succinate, or mixtures thereof.

Optionally, the wrapping material that is produced can also be treated with the tobacco soluble portion, such as the concentrated tobacco soluble portion that was separated from the insoluble fraction. The tobacco soluble portion can be applied to the web using various application methods, such as spraying, using a size press, saturating, etc. In one embodiment, the tobacco solubles can be applied to the formed web in an amount greater than about 5% by weight, such as in an amount greater than about 10% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 18% by weight based upon the dry weight of the web. In general, the tobacco solubles or tobacco extract is applied to the wrapping material in an amount less than about 20%, based upon the dry weight of the web.

In addition to a humectant, a burn control agent, and/or the tobacco extract, the wrapping material made according to the present disclosure can be treated with various other agents and ingredients. For instance, in one embodiment, one or more flavoring agents can also be added to the web.

The finished web or wrapper is dried and wound into rolls. For instance, in one embodiment, the dried sheet is wound into bobbins having a width of from about 15 mm to about 54 mm, such as from about 19 mm to about 28 mm. Prior to winding the web into a bobbin, the web may be calendered to increase the smoothness and runnability of the material. In one embodiment, for instance, a multi-nip calendar device may be used.

The resulting wrapping material made in accordance with the present disclosure contains the tobacco material generally in an amount greater than about 10% by weight. For instance, tobacco material can be contained in the wrapping material in an amount greater than about 15% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 25% by weight. The tobacco material is generally contained in the wrapper in an amount less than about 60% by weight, such as in an amount less than about 50% by weight, such as in an amount less than about 40% by weight, such as in an amount less than about 30% by weight.

The bleached pulp fibers and the filler can be contained in the wrapping material at different levels depending upon the particular application and the desired result. The bleached pulp fibers, for instance, can be present in the wrapping material generally in an amount greater than about 20% by weight, such as in an amount greater than about 25% by weight, and generally in an amount less than about 50% by weight, such as in an amount less than about 40% by weight, such as in an amount less than about 35% by weight. The filler is generally contained in the wrapping material in an amount greater than about 10% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 20% by weight, and generally in an amount less than about 35% by weight, such as in an amount less than about 30% by weight, such as in an amount less than about 25% by weight.

When present, the humectant and burn control agent are generally present in the wrapping material in amounts less than about 5% by weight, such as in amounts less than about 3% by weight, such as in amounts less than about 2% by weight, such as in amounts less than about 1.5% by weight, such as in amounts less than about 1% by weight. The humectant and/or the burn control agent can be present in the wrapping material generally in an amount greater than about 1% by weight, such as in an amount greater than about 1.5% by weight.

Wrapping materials made in accordance with the present disclosure have excellent mechanical characteristics and have a very desirable and aesthetic appearance. In general, the wrapping material has a basis weight of greater than about 30 gsm, such as greater than about 35 gsm, such as greater than about 40 gsm. The basis weight of the wrapping material is generally less than about 55 gsm, such as less than about 50 gsm, such as less than about 45 gsm. Within the above basis weights, the wrapping material is very strong and can exhibit a tensile strength of greater than about 1,000 cN/15 mm, such as greater than about 1,500 cN/15 mm and generally less than about 3,000 cN/15 mm. Tensile strength can be measured using ASTM Test D828-97.

In addition to the above physical properties, the wrapping material made in accordance with the present disclosure can exhibit a distinct natural appearance. In addition, the wrapping paper can have a brighter and whiter look than many conventional tobacco wrappers made from homogenized tobacco material.

In one embodiment, in order to characterize the color of at least one side of the wrapping material, the color can be expressed objectively using the Hunter Lab color scale and specifying values for L, a, and b. The Hunter Lab color scale was created in 1948 by Richard S. Hunter and is described in “The Measurement of Appearance,” 2^(nd) Addition, John Wiley and Sons, New York, N.Y., 1987. It describes all the colors visible to the human eye and was created to serve as a device-independent model to be used as a reference.

The three coordinates of the Hunter Lab scale represent the lightness of the color (L=0 yields black and L=100 indicates diffuse white; specular white may be higher), its position between red/magenta and green (a, negative values indicate green while positive values indicate magenta) and its position between yellow and blue (b, negative values indicate blue and positive values indicate yellow).

In accordance with the present disclosure, at least one side of the wrapping paper can generally have an L value of greater than about 60, such as greater than about 70, such as greater than about 75, such as greater than about 78. When the wrapping material is treated with the tobacco solubles or tobacco extract, the L value is slightly decreased. For instance, when the wrapping material is treated with the tobacco solubles, the wrapper can have an L value of generally greater than about 65, such as greater than about 70. When the wrapping material is not treated with the tobacco solubles, on the other hand, the L value is generally greater than about 75, such as greater than about 78. The L value of the wrapping material is generally less than about 98, such as less than about 95.

In addition to exhibiting a bright white color, the wrapping material of the present disclosure also has a speckled appearance due to the presence of the larger tobacco particles and fibers. The speckled appearance due to the presence of the tobacco material creates a distinct natural appearance in conjunction with the increased whiter look.

The wrapping material of the present disclosure also produces smoking articles having better taste properties. For instance, the wrapping material of the present disclosure produces a less papery taste than conventional cigarette papers. In addition, a smoother smoke is produced. In addition, the wrapping material produces a cohesive ash with an improved appearance against conventional tobacco wrappers.

Wrapping materials made according to the present disclosure can be incorporated into all different types of smoking articles. For illustrative purposes only, one such smoking article is shown in FIGS. 1-2. As shown, the smoking article 10 includes a smokable column 12. The smoking article 10 may also include a wrapper 14 that defines an outer circumferential surface 16 when wrapped around the smokable column 12. The article 10 may also include a filter 26 that may be enclosed by a tipping paper.

The smoking article shown in FIGS. 1 and 2 generally comprises a cigarette. In other embodiments, however, the wrapping material of the present disclosure can be used to produce cigarillos and little cigars. For instance, referring to FIG. 3, one example of a cigarillo 30 is shown. The cigarillo 30 includes a column of smokable filler 32 surrounded by a wrapping material 34 made in accordance with the present disclosure. Optionally, the cigarillo 30 can include a plastic tip 36.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims. 

1. A wrapping material for smoking articles comprising: a web containing at least 10% by weight tobacco material, the tobacco material comprising tobacco particles or tobacco fibers, the tobacco material having a particle size distribution such that greater than 80% of the material has a largest dimension of greater than about 0.012 inch, the tobacco material being blended with bleached pulp fibers and a filler, the bleached pulp fibers being present in the web in an amount greater than about 20% by weight, the filler being present in the web in an amount greater than about 10% by weight, the filler comprising white particles.
 2. A wrapping material as defined in claim 1, wherein at least one side of the wrapping material has a white color such that the color of the side of the wrapping material has an L value of greater than about
 65. 3. A wrapping material as defined in claim 1, wherein the web contains the tobacco material in an amount from about 10% to about 60% by weight.
 4. A wrapping material as defined in claim 1, wherein greater than 50% of the tobacco material comprises flue cured stems.
 5. A wrapping material as defined in claim 1, wherein the web contains the bleached pulp fibers in an amount from about 20% to about 50% by weight.
 6. A wrapping material as defined in claim 1, wherein the web contains the filler in an amount from about 10% to about 30% by weight.
 7. A wrapping material as defined in claim 1, wherein the filler comprises calcium carbonate particles.
 8. A wrapping material as defined in claim 1, wherein the filler contained in the wrapper has a particle size of from about 0.1 micron to about 2 microns.
 9. A wrapping material as defined in claim 1, wherein the wrapping material further comprises a humectant.
 10. A wrapping material as defined in claim 9, wherein the humectant comprises glycerol, propylene glycol, or mixtures thereof and the like.
 11. A wrapping material as defined in claim 1, wherein the wrapping material further comprises a burn control agent.
 12. A wrapping material as defined in claim 11, wherein the burn control agent comprises a citrate.
 13. A wrapping material as defined in claim 1, wherein the web has a porosity of from about 30 Coresta to about 80 Coresta, and has a basis weight of from about 30 gsm to about 50 gsm.
 14. A wrapping material as defined in claim 1, wherein the web has a tensile strength of greater than about 1500 cN/15 mm.
 15. A wrapping material as defined in claim 1, wherein the web has been calendered.
 16. A wrapping material as defined in claim 1, wherein greater than about 90% of the tobacco material has a greatest dimension of greater than about 0.015 inch.
 17. A wrapping material as defined in claim 1, wherein the web has been treated with tobacco solubles extracted from the tobacco material by an aqueous solvent, the tobacco solubles having been topically applied to the web.
 18. A wrapping material as defined in claim 1, wherein the tobacco material contained in the web has a particle size distribution such that greater than 80% of the tobacco material has a greatest dimension of greater than about 0.025 inches.
 19. A wrapping material as defined in claim 1, wherein the one side of the wrapping material has an L of greater than about
 70. 20. A wrapping material as defined in claim 1, wherein the web comprises a wetlaid web. 